WO1991011324A1 - Ameliorations apportees a un materiau composite thermoplastique - Google Patents

Ameliorations apportees a un materiau composite thermoplastique Download PDF

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Publication number
WO1991011324A1
WO1991011324A1 PCT/GB1991/000132 GB9100132W WO9111324A1 WO 1991011324 A1 WO1991011324 A1 WO 1991011324A1 GB 9100132 W GB9100132 W GB 9100132W WO 9111324 A1 WO9111324 A1 WO 9111324A1
Authority
WO
WIPO (PCT)
Prior art keywords
polymer base
mat
layers
polymeric layer
thermoplastic
Prior art date
Application number
PCT/GB1991/000132
Other languages
English (en)
Inventor
Andrew Nicholas Ferrar
David Donald Phin
Original Assignee
Don & Low (Holdings) Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Don & Low (Holdings) Limited filed Critical Don & Low (Holdings) Limited
Priority to DE1991903501 priority Critical patent/DE513121T1/de
Publication of WO1991011324A1 publication Critical patent/WO1991011324A1/fr
Priority to US08/312,684 priority patent/US5578370A/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D1/00—Woven fabrics designed to make specified articles
    • D03D1/0035—Protective fabrics
    • D03D1/0052—Antiballistic fabrics
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/573—Tensile strength
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/587—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads adhesive; fusible
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/514—Oriented
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2377/00—Polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2571/00—Protective equipment
    • B32B2571/02—Protective equipment defensive, e.g. armour plates or anti-ballistic clothing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2597/00—Tubular articles, e.g. hoses, pipes
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
    • D10B2321/021—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polyethylene
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
    • D10B2321/022—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polypropylene
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/04—Heat-responsive characteristics
    • D10B2401/041—Heat-responsive characteristics thermoplastic; thermosetting
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D10B2401/063—Load-responsive characteristics high strength
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2503/00—Domestic or personal
    • D10B2503/04—Floor or wall coverings; Carpets
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
    • Y10T428/2931—Fibers or filaments nonconcentric [e.g., side-by-side or eccentric, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core
    • Y10T428/2938—Coating on discrete and individual rods, strands or filaments
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core
    • Y10T428/2964—Artificial fiber or filament
    • Y10T428/2967—Synthetic resin or polymer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
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    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core
    • Y10T428/2964—Artificial fiber or filament
    • Y10T428/2967—Synthetic resin or polymer
    • Y10T428/2969—Polyamide, polyimide or polyester
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2973—Particular cross section
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3033—Including a strip or ribbon
    • Y10T442/3041—Woven fabric comprises strips or ribbons only
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/40—Knit fabric [i.e., knit strand or strip material]
    • Y10T442/406—Including parallel strips
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]

Definitions

  • This invention relates to a thermoplastic composite material and a method of its production.
  • the composite material is suitable for a variety of applications
  • Such applications include, by way of example, carpet backings and reinforced sheet materials for general engineering applications.
  • a primary backing into which tufts are inserted to form the pile of the carpet.
  • a secondary carpet backing very often in the form of a foamed or woven
  • the primary backing is then applied to the rear face of the tufted primary backing in order to cover the tufts in position within the primary backing.
  • a variety of materials can be used for the primary backing but it is common to form the primary backing of woven polypropylene tapes.
  • Polypropylene is utilised because it is cost-effective.
  • the polypropylene tape can be fibrillated in order to permit easy needle penetration and at the same time provide high residual strength in the finished carpet.
  • the fabric formed by the woven polypropylene as the primary backing results in a product which has limited dimensional stability and, if the carpet or carpet tile is cut, then frayed edges result.
  • U.S. Patent No. 3,533,893 discloses a primary carpet backing having a laminate made up of a continuous film of a high melting point polymer and a continuous film of a lower melting point polymer. Tufts of a textile material are passed through the laminate after formation thereof to form a tufted pile fabric.
  • the film of lower melting point polymer is specifically disclosed as being
  • polyethylene are useful to an extent, polyethylene has disadvantages in that it does not easily bond with
  • polypropylene and in many cases has to be secured thereto by means of an adhesive or primer. It is thought that because of the difficulty in bonding polyethylene to polypropylene, surface layers of polyethylene do not provide adequate protection during a drawing operation to effect molecular orientation of the polypropylene in order to increase its strength. As a result such
  • polyethylene-coated polypropylene tapes can suffer from unacceptable breakage of the tape during drawing operations particularly at high draw ratios.
  • One of the objects of the present invention is to provide a means of producing composite elongated elements such as tape which can be used to produce a fabric
  • thermoplastic composite material comprising at least one mat of mutually intersecting elongate elements fusible together at least at their intersections, each of said elements comprising a molecularly-oriented thermoplastic polymer base having at least one thermoplastic surface polymeric layer compatibly bonded to said polymer base by molecular interspersion between the contiguous surfaces of the adjoining base and surface layers, and said surface polymeric layer having a softening temperature lower than that of the polymer base.
  • an elongated thermoplastic composite material comprising a molecularly-oriented thermoplastic polymer base having at least one thermoplastic surface polymeric layer compatibly bonded to said polymer base by molecular interspersion between the contiguous surfaces of the adjoining base and surface layers, and said surface polymeric layer having a softening temperature lower than that of the polymer base.
  • molecular interspersion is meant the intimate molecular compatability of molecules of the surface layer and the adjacent polymer base and vice versa so that there is intermingling or fusion at their contiguous
  • interspersion effectively forms an amorphous sheath which protects the polymer base against fracture during drawing thus providing mutual mechanical reinforcement.
  • Mutual mechanical reinforcement involves the surface material being capable of high elongation when drawn in the solid state (or even being drawn at a temperature above its softening point, i.e. in the molten state).
  • the oriented thermoplastic polymer base is a polyolefin polymer such as polypropylene, a polyester such as polyethyleneterephthalate, a polyamide such as Nylon 6 or 6.6, or a polyethylene having a density in the range 0.940 to 0.970 or linear low density polyethylene.
  • each surface layer is an ethylene-propylene co-polymer, a polybutylene such as polybutene-1, or a co-polymer comprising two or more of butylene, ethylene and propylene.
  • the surface layers can be a co-polyester and when the polymer base is a polyamide can be a co-polyamide.
  • each mat of intersecting elongate elements is formed by weaving, knitting or by laying down of a random fibrous web.
  • thermoplastic composite material comprising providing a plurality of elongate elements each comprising a molecularly oriented thermoplastic polymer base having at least one
  • thermoplastic surface polymeric layer compatibly bonded thereto by molecular interspersion between contiguous surfaces of the adjoining base and surface layers, and said surface layer having a softening temperature lower than that of the polymer base; forming a mat of mutually intersecting elongate elements; heating said mat at a temperature at or above the softening temperature of each surface polymeric layer but below the softening
  • heating of the mat is effected within or in relation to a mould or former whereby, on cooling, the mat assumes a predetermined three-dimensional form.
  • the method comprises, prior to fusion, forming a stack of two or more superimposed mats of intersecting elongate elements; and heating the stack to form a multilayered sheet.
  • the axes of orientation of the elongate elements may be angularly displaced relative to the elements in the adjacent mat so as to provide a cross-laid, balanced structure.
  • a fabric suitable for use as the primary backing of a tufted carpet is formed from a film of mono-axially oriented polyolefin polymer such as polypropylene.
  • the film is formed by extrusion and stretched along a single axis.
  • the polypropylene film has a softening range of around 165°C.
  • the pre-formed polypropylene film is then coated on both sides thereof with a surface layer of a polymeric material such as an ethylene-propylene
  • the composite film is then slit to form a plurality of separate elongate elements in the form of tapes, each tape consisting of a central polypropylene base or core having bonded thereto on each face thereof a surface layer of the ethylene-propylene co-polymer having a lower softening temperature than that of the
  • the tape thus formed is then drawn at a draw ratio of the order of 20:1 in order to effect
  • the molten co-polymer surface layers permit this degree of consistent drawing to an extent which is greater than that which would be permitted if, for example, polyethylene was used as a surface layer.
  • the tape is then woven in known manner to form a fabric or mat suitable for use as a primary backing of a tufted carpet.
  • the warp and weft tapes may be fibrillated to ease needle penetration.
  • the backing is passed to a tufting machine for insertion of the carpet tufts, again in accordance with known practice.
  • the tufted primary backing is then passed to a heating station where heat is applied at a temperature sufficient to soften the co-polymer surface layers of the primary backing so that, at the inter-sections of the warp and weft tapes, the tapes become fused together.
  • the selected temperature is less than 165°C so that it is below the softening temperature of the polypropylene core in order that little loss of orientation or strength occurs in the core.
  • the woven tapes of the primary backing are integrated by fusion.
  • the sheet thus formed provides a primary backing with excellent dimensional strength and stability and is also one whichdoes not fray at the edges if cut. Fusing of the adjacent tapes together also tends to lock the individual tufts of the carpet into the primary backing in a manner which is more secure than with previously proposed
  • a primary backing produced in accordance with the present invention can have a tensile strength considerably in excess of that of previously proposed carpet backings in which polyethylene is used as the surface layer.
  • polymeric layers can be an amorphous layer constituted preferably by an ethylene-propylene co-polymer but other polymers such as polybutene-1, or a co-polymer of two or more polymers selected from butylene, ethylene and
  • propylene can also be employed.
  • the primary backing is described as being formed with a surface polymeric layer on both faces of the polypropylene film. It would, of course, be possible to provide a surface layer only on one side of the polypropylene film. Also, the
  • polypropylene film can be oriented bi-axially rather than mono-axially.
  • the composite film can be produced by co-extrusion of separate melt streams which are brought together and cooled to form a core layer of polypropylene to which is bonded on one or both sides a surface polymeric layer having a lower softening point than the polypropylene.
  • the polymer of the surface layer can be formulated to have dye acceptance with acid dye
  • the composite tapes are formed as in Example l described above and woven in the usual way to form a woven primary backing fabric or mat.
  • the tufted primary carpet backing is heated whilst constrained in a shaped mould or former.
  • the applied heat then softens the thermoplastic outer layers and the product is then allowed to cool thereby producing a carpet having a three-dimensional form dictated by the shape of the mould or former.
  • Such a carpet product is useful in carpets for use, for example, in the interiors of automobiles where a carpet may have to conform to the well of the vehicle floor.
  • This Example relates to the manufacture of a
  • thermoplastic composite material suitable for general engineering applications.
  • the material is produced from a tape having a polypropylene (PP) core provided on both sides with a surface layer or cap coat of a random co-polymer of ethylene-propylene (EP).
  • the polypropylene core is a polypropylene homo-polymer of 3.5 melt flow index (MFI).
  • MFI melt flow index
  • the EP/PP/EP tape structure has relative cross-sectional thicknesses of 7/86/7 where such thicknesses are expressed as a percentage of the total cross-sectional thickness of the tape.
  • the polymers are cast as a film on to chill rolls, slit and drawn in a hot air oven at a draw ratio of 10:1 prior to annealing and winding on to packages suitable for weaving.
  • the tapes thus produced are 220 tex, 3 mm wide with a breaking force of 530 Newtons (N) and extension at failure of 14%.
  • the surface layers are compatibly bonded to the polypropylene core by molecular interspersion between the contiguous surfaces of the layers and core.
  • the tapes were used as both the warp and weft to produce a plain woven fabric having a tape count of 59 tapes per 10 cm width in the warp direction and 47 tapes per 10 cm width in the weft direction.
  • a plurality of layers or mats of this woven material were superimposed on each other and formed under heat and pressure in a single daylight press (10 Bar at 165°C) to produce a self-reinforcing laminate on cooling. It will be readily apparent that any suitable number of layers can be incorporated depending on the desired strength and application of the fabric. For example, 20 layers give an areal density of 4.7 kg/m 2 .
  • the tapes can have a mono-axial or biaxial orientation and when the mats are superimposed upon each other, the axes of orientation of the woven tapes in each adjacent mat can be angularly displaced relative to each other so as to provide a cross-laid balanced structure having high impact strength.
  • thermoplastic composite fabric is produced as described above in Example 3 with the
  • thermoplastic composite fabric is produced as described in foregoing Example 4 with the difference that the surface layers or cap coats of the tape are of a random co-polymer of ethylene/butylene instead of a co-polymer of ethylene/propylene.
  • This Example relates to the manufacture of an impact resistant sheet suitable for antiballistic protection.
  • tapes are co-extruded having a structure in which a polypropylene core has surface or cap layers on either side thereof of a random co-polymer of ethylene-propylene.
  • the polypropylene is a homo-polymer having a melt flow index MFI) of 3 and the EP/PP/EP tape structure has relative cross-sectional thicknesses of 7/86/7 where such thicknesses are expressed as a
  • the molten polymers are cast on to a chill roll to produce a composite film in which the surface layers are compatibly bonded to the polypropylene core by molecular interspersion between the contiguous surfaces of the layers and core.
  • the composite film emanating therefrom is then slit and drawn in a hot air oven at a draw ratio of 20:1 before being annealed and wound up on to a package as a 220 tex tape of width 3 mm with a breaking force of 600 Newtons (N) and extension at break of 10%.
  • tapes are used for both the warp and weft of a woven plain weave fabric having 59 tapes per 10 cm width in the warp direction and 47 tapes per 10 cm width in the weft direction.
  • the same tapes can also be woven to give a twill weave fabric having 40 tapes per 10 cm width in both warp and weft directions.
  • a plurality of layers or mats of the fabrics thus formed are superimposed on each other, crosslaid if desired as described in Example 3, and formed under heat and pressure to produce, on cooling, a rigid,
  • thermoplastic laminated composite material With a single daylight press, a composite material having an areal density of 10 kg/m 2 can be formed using a pressure of 10 Bar at a temperature of 165°C and dwell time of 20 minutes.
  • the number of layers used to form the composite material can be varied in accordance with requirements but in the present Example materials incorporating 43 layers or mats of plain weave or 57 layers or mats of twill weave have been employed.
  • Panels made from twill weave and plain weave tapes as described above were subjected to attack from a 9 mm weapon using full service charge to propel a ball at normal impact from 15 metres range, strike or impact velocities were in the range of 422-429 metres/second.
  • a standard impact velocity was measured in the tests, being the impact speed at which 50% of the ballistic missiles were stopped by the panel whilst the remaining 50% were passed through.
  • a standard impact velocity (V 50 ) of 421 metres/second was achieved with a panel utilising a twill weave areal density of 10.68 kg/m 2 and with a panel utilising a flat or plain weave areal density of 11.76 kg/m 2 . Both the plain and twill weave panels in
  • the multilayered composite sheet material as described above in Examples 3 to 6 can be used for a variety of other applications where strength is of importance e.g. for protective applications such as toe-caps for
  • the mat or mats of fabrics formed in accordance with the present invention can be moulded into a variety of shapes.
  • the fabric can be formed into a tube or pipe by spirally winding the fabrics or tapes about a cylindrical mandrel.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

On décrit un matériau composite thermoplastique comprenant une base polymère thermoplastique à molécules orientées, comportant au moins une couche polymère superficielle thermoplastique liée de manière compatible à ladite base polymère par l'intercalation de molécules entre les surfaces continguës de la base adjacente et les couches superficielles, ladite couche polymère superficielle étant caractérisée par une température de ramollissement inférieure à celle de la base polymère.
PCT/GB1991/000132 1990-02-02 1991-01-30 Ameliorations apportees a un materiau composite thermoplastique WO1991011324A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
DE1991903501 DE513121T1 (de) 1990-02-02 1991-01-30 Verbesserungen an einem thermoplastischen verbundmaterial.
US08/312,684 US5578370A (en) 1990-02-02 1994-09-27 Molecularly interspersed thermoplastic composite mat

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9002374.8 1990-02-02
GB909002374A GB9002374D0 (en) 1990-02-02 1990-02-02 Improvements in or relating to composite sheet material

Publications (1)

Publication Number Publication Date
WO1991011324A1 true WO1991011324A1 (fr) 1991-08-08

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US (1) US5578370A (fr)
EP (1) EP0513121A1 (fr)
JP (1) JPH05504107A (fr)
AU (1) AU645526B2 (fr)
CA (1) CA2100975A1 (fr)
GB (1) GB9002374D0 (fr)
NZ (1) NZ236960A (fr)
WO (1) WO1991011324A1 (fr)
ZA (1) ZA91730B (fr)

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GB2266322A (en) * 1992-03-26 1993-10-27 Don & Low Thermoplastic composite material
GB2279232A (en) * 1993-05-25 1995-01-04 Don & Low Blast containment structures
US5500284A (en) * 1993-12-27 1996-03-19 Montell North America Inc. Composite polyolefin films suitable for packaging
GB2492644A (en) * 2011-07-04 2013-01-09 Don & Low Ltd Polymer fabrics
US8663531B2 (en) 2004-06-18 2014-03-04 Samsonite Ip Holdings S.A.R.L. Process for making a luggage shell from self-reinforced thermo-plastic material
US9227346B2 (en) 2004-10-22 2016-01-05 Dow Global Technologies Llc Plastic composite articles and methods of making same
EP3553213A2 (fr) 2018-04-12 2019-10-16 Don & Low Limited Améliorations apportées ou se rapportant à des matériaux polymères

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US7294384B2 (en) * 2005-09-27 2007-11-13 Milliken & Company Moldable construction incorporating bonding interface
US7378359B2 (en) * 2005-09-27 2008-05-27 Eleazer Howell B Moldable fibrous construction incorporating non-woven layers
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Cited By (10)

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Publication number Priority date Publication date Assignee Title
GB2266322A (en) * 1992-03-26 1993-10-27 Don & Low Thermoplastic composite material
GB2279232A (en) * 1993-05-25 1995-01-04 Don & Low Blast containment structures
US5500284A (en) * 1993-12-27 1996-03-19 Montell North America Inc. Composite polyolefin films suitable for packaging
US8663531B2 (en) 2004-06-18 2014-03-04 Samsonite Ip Holdings S.A.R.L. Process for making a luggage shell from self-reinforced thermo-plastic material
EP2168754B1 (fr) 2004-06-18 2019-12-04 Samsonite IP Holdings S.à r.l. Armature d'une valise
US11363866B2 (en) 2004-06-18 2022-06-21 Samsonite Ip Holdings S.A R.L. Process for making a luggage shell from self-reinforced thermo-plastic material
US9227346B2 (en) 2004-10-22 2016-01-05 Dow Global Technologies Llc Plastic composite articles and methods of making same
GB2492644A (en) * 2011-07-04 2013-01-09 Don & Low Ltd Polymer fabrics
GB2492644B (en) * 2011-07-04 2018-12-05 Don & Low Ltd Improved polymer fabrics
EP3553213A2 (fr) 2018-04-12 2019-10-16 Don & Low Limited Améliorations apportées ou se rapportant à des matériaux polymères

Also Published As

Publication number Publication date
US5578370A (en) 1996-11-26
AU7227091A (en) 1991-08-21
AU645526B2 (en) 1994-01-20
NZ236960A (en) 1994-04-27
EP0513121A1 (fr) 1992-11-19
CA2100975A1 (fr) 1991-08-03
GB9002374D0 (en) 1990-04-04
JPH05504107A (ja) 1993-07-01
ZA91730B (en) 1991-11-27

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